Aerosol delivery device including a housing and a coupler

ABSTRACT

The present disclosure relates to aerosol delivery devices. The aerosol delivery devices may include a control body and a cartridge including an atomizer and a reservoir configured to contain an aerosol precursor composition. The control body may include a housing defining an electrical power source cavity that extends along a first longitudinal axis and is configured to receive an electrical power source. The control body may additionally include a coupler configured to engage a cartridge including an aerosol precursor composition such that the cartridge extends along a second longitudinal axis. The first longitudinal axis and the second longitudinal axis may be non-coaxial and oriented substantially parallel to one another. A related assembly method is also provided.

FIELD OF THE DISCLOSURE

The present disclosure relates to aerosol delivery devices, and moreparticularly, to aerosol delivery devices that include a housing and acoupler. The aerosol delivery device may include an atomizer comprisinga heating element configured to heat an aerosol precursor. The aerosolprecursor composition, which may include components made or derived fromtobacco or otherwise incorporate tobacco, is heated by the atomizer toproduce an inhalable substance for human consumption.

BACKGROUND

Many smoking devices have been proposed through the years asimprovements upon, or alternatives to, smoking products that requirecombusting tobacco for use. Many of those devices purportedly have beendesigned to provide the sensations associated with cigarette, cigar orpipe smoking, but without delivering considerable quantities ofincomplete combustion and pyrolysis products that result from theburning of tobacco. To this end, there have been proposed numeroussmoking products, flavor generators and medicinal inhalers that utilizeelectrical energy to vaporize or heat a volatile material, or attempt toprovide the sensations of cigarette, cigar or pipe smoking withoutburning tobacco to a significant degree. See, for example, the variousalternative smoking articles, aerosol delivery devices and heatgenerating sources set forth in the background art described in U.S.Pat. No. 7,726,320 to Robinson et al. and U.S. Pat. No. 8,881,737 toCollett et al., which are incorporated herein by reference. See also,for example, the various types of smoking articles, aerosol deliverydevices and electrically-powered heat generating sources referenced bybrand name and commercial source in U.S. Pat. Pub. No. 2015/0216232 toBless et al., which is incorporated herein by reference. Additionally,various types of electrically powered aerosol and vapor delivery devicesalso have been proposed in U.S. Pat. App. Pub. Nos. 2014/0096781 toSears et al. and 2014/0283859 to Minskoff et al., as well as U.S. patentapplication Ser. No. 14/282,768 to Sears et al., filed May 20, 2014;Ser. No. 14/286,552 to Brinkley et al., filed May 23, 2014; Ser. No.14/327,776 to Ampolini et al., filed Jul. 10, 2014; and Ser. No.14/465,167 to Worm et al., filed Aug. 21, 2014; all of which areincorporated herein by reference.

Certain existing embodiments of aerosol delivery devices include acontrol body and a cartridge. A power source (e.g., a battery) may bepositioned in the control body and an aerosol precursor composition maybe positioned in the cartridge. The cartridge and the control body mayengage one another to define an elongated tubular configuration.However, certain other form factors for aerosol delivery devices may bedesirable.

BRIEF SUMMARY OF THE DISCLOSURE

The present disclosure relates to aerosol delivery devices which, incertain embodiments, may be characterized as electronic cigarettes. Inone aspect an aerosol delivery device is provided. The aerosol deliverydevice may include a housing. The housing may define an electrical powersource cavity configured to receive an electrical power source, and acartridge cavity configured to receive a cartridge including an aerosolprecursor composition. The electrical power source cavity and thecartridge cavity may be elongated and respectively define a longitudinalaxis. The longitudinal axis of the electrical power source cavity andthe longitudinal axis of the cartridge cavity may be non-coaxial andoriented substantially parallel to one another.

In some embodiments the aerosol delivery device may further include theelectrical power source. Additionally, the aerosol delivery device mayinclude the cartridge. Further, the aerosol delivery device may includea coupler positioned within the housing and configured to engage thecartridge. The aerosol delivery device may additionally include an outercover engaged with an exterior of the housing.

In some embodiments the housing may further define a viewing opening atthe cartridge cavity. Additionally, the aerosol delivery device mayinclude an illumination source configured to illuminate the cartridge inthe cartridge cavity. The aerosol delivery device may further include anelectronic display. The housing may include an access door configured toprovide access to the electrical power source cavity. The housing maydefine an external opening at the cartridge cavity configured to receivethe cartridge therethrough. The housing may define a dividing wall thatseparates the electrical power source cavity from the cartridge cavity.

In an additional aspect a method for assembling an aerosol deliverydevice is provided. The method may include providing a housing. Thehousing may define an electrical power source cavity configured toreceive an electrical power source and a cartridge cavity configured toreceive a cartridge including an aerosol precursor composition. Theelectrical power source cavity and the cartridge cavity may be elongatedand respectively define a longitudinal axis. The longitudinal axis ofthe electrical power source cavity and the longitudinal axis of thecartridge cavity may be non-coaxial and oriented substantially parallelto one another. Further, the method may include positioning anelectrical contact in the electrical power source cavity. The electricalcontact may be configured to engage the electrical power source.Additionally, the method may include positioning a coupler in thecartridge cavity. The coupler may be configured to engage the cartridge.

In some embodiments the method may further include inserting theelectrical power source in the electrical power source cavity andengaging the electrical power source with the electrical contact.Additionally, the method may include inserting the cartridge into thecartridge cavity and engaging the cartridge with the coupler. Insertingthe cartridge into the cartridge cavity may include inserting thecartridge through an external opening defined by the housing.

In some embodiments providing the housing may include defining a viewingopening at the cartridge cavity. Further, the method may includeengaging an outer cover with an exterior of the housing. The method mayadditionally include positioning an illumination source in the housing.The illumination source may be configured to illuminate the cartridge inthe cartridge cavity. In some embodiments the method may additionallyinclude engaging an electronic display with the housing. Providing thehousing may include engaging a first body portion with a second bodyportion. Providing the housing further may further include engaging anaccess door with at least one of the first body portion and the secondbody portion. The access door may be configured to selectively provideaccess to the electrical power source cavity.

In an additional aspect an aerosol delivery device is provided. Theaerosol delivery device may include a housing defining an electricalpower source cavity configured to receive an electrical power source.The electrical power source cavity may define a first longitudinal axis.The aerosol delivery device may additionally include a coupler engagedwith the housing and configured to engage a cartridge including anaerosol precursor composition such that the cartridge extends along asecond longitudinal axis. The first longitudinal axis and the secondlongitudinal axis may be non-coaxial and oriented substantially parallelto one another.

In some embodiments the aerosol delivery device may further include theelectrical power source. Additionally, the aerosol delivery device mayinclude a controller. The controller may be wrapped at least partiallyabout the electrical power source.

In some embodiments the aerosol delivery device may further include thecartridge. The cartridge may include a viewing window. The aerosoldelivery device may additionally include an illumination sourceconfigured to direct illumination through the viewing window.

In some embodiments the housing may include a coupler portion. Thecoupler may be positioned at least partially within the coupler portion.The housing may include a button assembly. The button assembly may beconfigured to control a power output level directed from the electricalpower source to the cartridge. The button assembly may at leastpartially define a dividing wall that separates the cartridge from theelectrical power source cavity. Further, the aerosol delivery device mayinclude an illumination source. The button assembly may include anillumination source cover configured to direct illumination produced bythe illumination source therethrough.

In an additional aspect a method for assembling an aerosol deliverydevice is provided. The method may include providing a housing definingan electrical power source cavity configured to receive an electricalpower source. The electrical power source cavity may define a firstlongitudinal axis. The method may additionally include engaging acoupler configured to engage a cartridge including an aerosol precursorcomposition with the housing such that the cartridge extends along asecond longitudinal axis. The first longitudinal axis and the secondlongitudinal axis may be non-coaxial and oriented substantially parallelto one another. Further, the method may include positioning a controllerin the housing. The controller may be configured to engage theelectrical power source.

In some embodiments the method may further include engaging theelectrical power source with the controller. Additionally, the methodmay include inserting the electrical power source in the electricalpower source cavity simultaneously with positioning the controller inthe housing. Further, the method may include engaging the cartridge withthe coupler. The cartridge may include a viewing window. Further, themethod may include positioning an illumination source in the housing.The illumination source may be configured to direct illumination throughthe viewing window.

In some embodiments providing the housing may include engaging a firstbody portion with a second body portion. Further, providing the housingfurther may include engaging an access door with at least one of thefirst body portion and the second body portion. The access door may beconfigured to block access to the electrical power source cavity.Providing the housing may further include engaging a button assemblywith at least one of the first body portion and the second body portion.The method may additionally include positioning an illumination sourcein the housing and engaging an illumination source cover with the buttonassembly. The illumination source cover may be configured to directillumination produced by the illumination source therethrough.

These and other features, aspects, and advantages of the disclosure willbe apparent from a reading of the following detailed descriptiontogether with the accompanying drawings, which are briefly describedbelow.

BRIEF DESCRIPTION OF THE FIGURES

Having thus described the disclosure in the foregoing general terms,reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale, and wherein:

FIG. 1 illustrates a side view of an aerosol delivery device including acontrol body and a cartridge according to an example embodiment of thepresent disclosure;

FIG. 2 illustrates a sectional, partially-exploded view through thecontrol body of the aerosol delivery device of FIG. 1 according to anexample embodiment of the present disclosure;

FIG. 3 illustrates a modified sectional view through the aerosoldelivery device of FIG. 1 according to an example embodiment of thepresent disclosure;

FIG. 4 illustrates an exploded view of an example embodiment of thecartridge of FIG. 1 including a reservoir substrate;

FIG. 5 illustrates a sectional view through an alternative exampleembodiment of the cartridge of FIG. 1 including a reservoir according toan example embodiment of the present disclosure;

FIG. 6 illustrates a modified sectional view through the aerosoldelivery device of FIG. 1 including the cartridge of FIG. 5 according toan example embodiment of the present disclosure;

FIG. 7 illustrates a perspective view of a control body including a sideopening configured to engage an outer cover and a relatively wideviewing opening according to an additional example embodiment of thepresent disclosure;

FIG. 8 illustrates a perspective view of the control body of FIG. 7 withthe outer cover according to an example embodiment of the presentdisclosure;

FIG. 9 illustrates an enlarged side view of the control body of FIG. 8at the viewing opening according to an example embodiment of the presentdisclosure;

FIG. 10 illustrates a section of a body portion of a housing of thecontrol body of FIG. 7 according to an example embodiment of the presentdisclosure;

FIG. 11 illustrates a perspective view of a control body including sideopenings configured to engage an outer cover and a relatively narrowviewing opening according to an additional example embodiment of thepresent disclosure;

FIG. 12 illustrates a section of a body portion of a housing of thecontrol body of FIG. 11 according to an example embodiment of thepresent disclosure;

FIG. 13 illustrates a bottom view of the control body of FIG. 11according to an example embodiment of the present disclosure;

FIG. 14 illustrates the control body of FIG. 11 with the outer coveraccording to an example embodiment of the present disclosure;

FIG. 15 illustrates an enlarged side view of the control body of FIG. 14at the viewing opening according to an example embodiment of the presentdisclosure;

FIG. 16 illustrates a method for assembling an aerosol delivery deviceaccording to an example embodiment of the present disclosure;

FIG. 17 illustrates a perspective view of an aerosol delivery deviceincluding a control body and a cartridge according to an exampleembodiment of the present disclosure;

FIG. 18 illustrates a partial exploded view of the control body of FIG.17 according to an example embodiment of the present disclosure;

FIG. 19 illustrates a partial side view of the control body of FIG. 17in a partially-assembled configuration including a first body portion ofa housing thereof according to an example embodiment of the presentdisclosure;

FIG. 20 illustrates a perspective view of a controller and an electricalpower source of the control body of FIG. 17 according to an exampleembodiment of the present disclosure;

FIG. 21 illustrates a perspective view of the control body of FIG. 17 ina partially-assembled configuration including a first body portion of ahousing thereof according to an example embodiment of the presentdisclosure;

FIG. 22 illustrates a perspective view of the control body of FIG. 17 ina partially-assembled configuration including an electrical power sourcehousing portion and a coupler portion of a housing thereof according toan example embodiment of the present disclosure;

FIG. 23 illustrates a sectional view through a coupler of the controlbody of FIG. 17 according to an example embodiment of the presentdisclosure; and

FIG. 24 illustrates a method for assembling an aerosol delivery deviceaccording to an example embodiment of the present disclosure.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present disclosure will now be described more fully hereinafter withreference to exemplary embodiments thereof. These exemplary embodimentsare described so that this disclosure will be thorough and complete, andwill fully convey the scope of the disclosure to those skilled in theart. Indeed, the disclosure may be embodied in many different forms andshould not be construed as limited to the embodiments set forth herein;rather, these embodiments are provided so that this disclosure willsatisfy applicable legal requirements. As used in the specification, andin the appended claims, the singular forms “a”, “an”, “the”, includeplural variations unless the context clearly dictates otherwise.

Aerosol delivery devices according to the present disclosure may useelectrical energy to heat a material (preferably without combusting thematerial to any significant degree) to form an inhalable substance; sucharticles most preferably being sufficiently compact to be considered“hand-held” devices. An aerosol delivery device may provide some or allof the sensations (e.g., inhalation and exhalation rituals, types oftastes or flavors, organoleptic effects, physical feel, use rituals,visual cues such as those provided by visible aerosol, and the like) ofsmoking a cigarette, cigar, or pipe, without any substantial degree ofcombustion of any component of that article or device. The aerosoldelivery device may not produce smoke in the sense of the aerosolresulting from by-products of combustion or pyrolysis of tobacco, butrather, that the article or device most preferably yields vapors(including vapors within aerosols that can be considered to be visibleaerosols that might be considered to be described as smoke-like)resulting from volatilization or vaporization of certain components ofthe article or device, although in other embodiments the aerosol may notbe visible. In highly preferred embodiments, aerosol delivery devicesmay incorporate tobacco and/or components derived from tobacco. As such,the aerosol delivery device can be characterized as an electronicsmoking article such as an electronic cigarette.

Aerosol delivery devices of the present disclosure also can becharacterized as being vapor-producing articles or medicament deliveryarticles. Thus, such articles or devices can be adapted so as to provideone or more substances (e.g., flavors and/or pharmaceutical activeingredients) in an inhalable form or state. For example, inhalablesubstances can be substantially in the form of a vapor (i.e., asubstance that is in the gas phase at a temperature lower than itscritical point). Alternatively, inhalable substances can be in the formof an aerosol (i.e., a suspension of fine solid particles or liquiddroplets in a gas). For purposes of simplicity, the term “aerosol” asused herein is meant to include vapors, gases and aerosols of a form ortype suitable for human inhalation, whether or not visible, and whetheror not of a form that might be considered to be smoke-like.

In use, aerosol delivery devices of the present disclosure may besubjected to many of the physical actions employed by an individual inusing a traditional type of smoking article (e.g., a cigarette, cigar orpipe that is employed by lighting and inhaling tobacco). For example, anaerosol delivery device of the present disclosure can be hand-held by auser, a user can draw on a portion of the article for inhalation ofaerosol produced by that article, a user can take puffs at selectedintervals of time, and the like.

Aerosol delivery devices of the present disclosure generally include ahousing and a number of additional components coupled thereto and/orpositioned within the housing, and some of the components may beremovable or replaceable. The overall design of the housing can vary,and the overall size and shape of the housing can vary. The smokingarticles can include a cartridge, which can be defined by an outer bodyor cover—e.g., an elongated body resembling the shape of a portion of acigarette or cigar. For example, an outer cover or body of the cartridgecan be substantially tubular in shape and, as such, resemble the shapeof a conventional cigarette or cigar. In some embodiments, the housingmay contain one or more reusable components (e.g., a rechargeablebattery and various electronics for controlling the operation of thatarticle), and the cartridge can be removable, refillable, and/ordisposable.

Aerosol delivery devices of the present disclosure most preferablycomprise some combination of a power source (i.e., an electrical powersource), at least one control component (e.g., means for actuating,controlling, regulating and/or ceasing power for heat generation, suchas by controlling electrical current flow from the power source to othercomponents of the aerosol delivery device), a heater or heat generationcomponent (e.g., an electrical resistance heating element or componentcommonly referred to as part of an “atomizer”), and an aerosol precursorcomposition (e.g., commonly a liquid capable of yielding an aerosol uponapplication of sufficient heat, such as ingredients commonly referred toas “smoke juice,” “e-liquid” and “e juice”), and a mouthend region ortip for allowing draw upon the aerosol delivery device for aerosolinhalation (e.g., a defined air flow path through the article such thataerosol generated can be withdrawn therefrom upon draw). When theheating element heats the aerosol precursor composition, an aerosol isformed, released, or generated in a physical form suitable forinhalation by a consumer. It should be noted that the foregoing termsare meant to be interchangeable such that reference to release,releasing, releases, or released includes form or generate, forming orgenerating, forms or generates, and formed or generated. Specifically,an inhalable substance is released in the form of a vapor or aerosol ormixture thereof.

As noted above, the aerosol delivery device may incorporate a batteryand/or other electrical power source (e.g., a capacitor) to providecurrent flow sufficient to provide various functionalities to theaerosol delivery device, such as powering of a heater, powering ofcontrol systems, powering of indicators, and the like. The power sourcecan take on various embodiments. Preferably, the power source is able todeliver sufficient power to rapidly heat the heating element to providefor aerosol formation and power the aerosol delivery device through usefor a desired duration of time. The power source preferably is sized tofit conveniently within the aerosol delivery device so that the aerosoldelivery device can be easily handled. Additionally, a preferred powersource is of a sufficiently light weight to not detract from a desirablesmoking experience. A battery for use in the present devices may bereplaceable, removable, and/or rechargeable and thus may be combinedwith any type of recharging technology, including connection to atypical alternating current electrical outlet, connection to a carcharger (i.e., a cigarette lighter receptacle), and connection to acomputer, such as through a universal serial bus (USB) cable orconnector. In one preferred embodiment the electrical power sourcecomprises a lithium-ion battery, which may light weight, rechargeable,and provide a large energy storage capacity. Examples of electricalpower sources are described in U.S. Pat. App. Pub. No. 2010/0028766 toPeckerar et al., the disclosure of which is incorporated herein byreference in its entirety.

An aerosol delivery device according to the present disclosurepreferably incorporates a sensor or detector for control of supply ofelectric power to a heat generation element when aerosol generation isdesired (e.g., upon draw during use). As such, for example, there isprovided a manner or method for turning off the power supply to the heatgeneration element when the aerosol generating piece is not be drawnupon during use, and for turning on the power supply to actuate ortrigger the generation of heat by the heat generation element duringdraw. For example, with respect to a flow sensor, representative currentregulating components and other current controlling components includingvarious microcontrollers, sensors, and switches for aerosol deliverydevices are described in U.S. Pat. No. 4,735,217 to Gerth et al.; U.S.Pat. No. 4,947,874 to Brooks et al.; U.S. Pat. No. 5,372,148 toMcCafferty et al.; U.S. Pat. No. 6,040,560 to Fleischhauer et al.; U.S.Pat. No. 7,040,314 to Nguyen et al.; U.S. Pat. No. 8,205,622 to Pan; andU.S. Pat. No. 8,881,737 to Collet et al.; U.S. Pat. Pub. Nos.2009/0230117 to Fernando et al.; and 2014/0270727 to Ampolini et al.;and 2015/0257445 to Henry et al.; which are incorporated herein byreference in their entireties. Additional representative types ofsensing or detection mechanisms, structures, components, configurations,and general methods of operation thereof, are described in U.S. Pat. No.5,261,424 to Sprinkel, Jr.; U.S. Pat. No. 5,372,148 to McCafferty etal.; and PCT WO 2010/003480 to Flick; which are incorporated herein byreference in their entireties.

In some embodiments, the aerosol delivery device can include anindicator, which may comprise one or more light emitting diodes. Theindicator can be in communication with the control component through aconnector circuit and illuminate, for example, during a user draw on themouthend as detected by the flow sensor.

Various elements that may be included in the housing are described inU.S. App. Pub. No. 2015/0245658 to Worm et al., which is incorporatedherein by reference in its entirety. Still further components can beutilized in the aerosol delivery device of the present disclosure. Forexample, U.S. Pat. No. 5,154,192 to Sprinkel et al. discloses indicatorsfor smoking articles; U.S. Pat. No. 5,261,424 to Sprinkel, Jr. disclosespiezoelectric sensors that can be associated with the mouth-end of adevice to detect user lip activity associated with taking a draw andthen trigger heating; U.S. Pat. No. 5,372,148 to McCafferty et al.discloses a puff sensor for controlling energy flow into a heating loadarray in response to a pressure drop through a mouthpiece; U.S. Pat. No.5,967,148 to Harris et al. discloses receptacles in a smoking devicethat include an identifier that detects a non-uniformity in infraredtransmissivity of an inserted component and a controller that executes adetection routine as the component is inserted into the receptacle; U.S.Pat. No. 6,040,560 to Fleischhauer et al. describes a defined executablepower cycle with multiple differential phases; U.S. Pat. No. 5,934,289to Watkins et al. discloses photonic-optronic components; U.S. Pat. No.5,954,979 to Counts et al. discloses means for altering draw resistancethrough a smoking device; U.S. Pat. No. 6,803,545 to Blake et al.discloses specific battery configurations for use in smoking devices;U.S. Pat. No. 7,293,565 to Griffen et al. discloses various chargingsystems for use with smoking devices; U.S. Pat. No. 8,402,976 toFernando et al. discloses computer interfacing means for smoking devicesto facilitate charging and allow computer control of the device; U.S.Pat. No. 8,689,804 to Fernando et al. discloses identification systemsfor smoking devices; and WO 2010/003480 to Flick discloses a fluid flowsensing system indicative of a puff in an aerosol generating system; allof the foregoing disclosures being incorporated herein by reference intheir entireties. Further examples of components related to electronicaerosol delivery articles and disclosing materials or components thatmay be used in the present article include U.S. Pat. No. 4,735,217 toGerth et al.; U.S. Pat. No. 5,249,586 to Morgan et al.; U.S. Pat. No.5,666,977 to Higgins et al.; U.S. Pat. No. 6,053,176 to Adams et al.;U.S. Pat. No. 6,164,287 to White; U.S. Pat. No. 6,196,218 to Voges; U.S.Pat. No. 6,810,883 to Felter et al.; U.S. Pat. No. 6,854,461 to Nichols;U.S. Pat. No. 7,832,410 to Hon; U.S. Pat. No. 7,513,253 to Kobayashi;U.S. Pat. No. 7,896,006 to Hamano; U.S. Pat. No. 6,772,756 to Shayan;U.S. Pat. Nos. 8,156,944 and 8,375,957 to Hon; U.S. Pat. No. 8,794,231to Thorens et al.; U.S. Pat. No. 8,851,083 to Oglesby et al.; U.S. Pat.Nos. 8,915,254 and 8,925,555 to Monsees et al.; U.S. Pat. App. Pub. Nos.2006/0196518 and 2009/0188490 to Hon; U.S. Pat. App. Pub. No.2010/0024834 to Oglesby et al.; U.S. Pat. App. Pub. No. 2010/0307518 toWang; WO 2010/091593 to Hon; WO 2013/089551 to Foo; and U.S. Pat. App.Pub. No. 2014/0261408 to DePiano et al., each of which is incorporatedherein by reference in its entirety.

The aerosol precursor composition, also referred to as a vapor precursorcomposition, may comprise a variety of components including, by way ofexample, any of a polyhydric alcohol (e.g., glycerin, propylene glycol,or a mixture thereof), nicotine, tobacco, tobacco extract, and/orflavorants. Various components that may be included in the aerosolprecursor composition are described in U.S. Pat. No. 7,726,320 toRobinson et al., which is incorporated herein by reference in itsentirety. Additional representative types of aerosol precursorcompositions are set forth in U.S. Pat. No. 4,793,365 to Sensabaugh, Jr.et al.; U.S. Pat. No. 5,101,839 to Jakob et al.; PCT WO 98/57556 toBiggs et al.; and Chemical and Biological Studies on New CigarettePrototypes that Heat Instead of Burn Tobacco, R. J. Reynolds TobaccoCompany Monograph (1988); the disclosures of which are incorporatedherein by reference in their entireties. Other aerosol precursors whichmay be employed in the aerosol delivery device of the present disclosureinclude the aerosol precursors included in the VUSE® product by R. J.Reynolds Vapor Company, the BLU™ product by Lorillard Technologies, theMistic Menthol product by Mistic Ecigs, and the Vype product by CNCreative Ltd. Also desirable are the so-called “Smoke Juices” forelectronic cigarettes that have been available from Johnson CreekEnterprises LLC. Additional exemplary formulations for aerosol precursormaterials that may be used according to the present disclosure aredescribed in U.S. Pat. Pub. No. 2013/0008457 to Zheng et al., and U.S.Pat. Pub. No. 2013/0213417 to Chong et al., the disclosures of which areincorporated herein by reference in their entireties.

The aerosol delivery device preferably includes a reservoir. In someembodiments, a reservoir may comprise a container for storing a liquidaerosol precursor, a fibrous substrate, or a combination of a fibroussubstrate and a container. A fibrous substrate suitable for use as areservoir may comprise a plurality of layers of nonwoven fibers and maybe formed substantially into the shape of a tube. For example, theformed tube may be shaped and sized for placement within the outer bodyor cover of a cartridge for use in the aerosol delivery device. Liquidcomponents, for example, can be sorptively retained by the fibroussubstrate and/or be retained within a reservoir container. The reservoirpreferably is in fluid connection with a liquid transport element. Thus,the liquid transport element may be configured to transport liquid fromthe reservoir to a heating element, such as via capillary action and/orvia active transport—e.g., pumping or controlled movement with a valve.Representative types of substrates, reservoirs, or other components forsupporting the aerosol precursor are described in U.S. Pat. No.8,528,569 to Newton; and U.S. Pat. App. Pub. Nos. 2014/0261487 toChapman et al.; 2014/0004930 to Davis et al.; and 2015/0216232 to Blesset al.; which are incorporated herein by reference in their entireties.

The liquid transport element may be in direct contact with the heatingelement. Various wicking materials, and the configuration and operationof those wicking materials within certain types of aerosol deliverydevices, are set forth in U.S. Pat. No. 8,910,640 to Sears et al., whichis incorporated herein by reference in its entirety. A variety of thematerials disclosed by the foregoing documents may be incorporated intothe present devices in various embodiments, and all of the foregoingdisclosures are incorporated herein by reference in their entireties.

The heating element may comprise a wire defining a plurality of coilswound about the liquid transport element. In some embodiments theheating element may be formed by winding the wire about the liquidtransport element as described in U.S. Pat. App. Pub. No. 2014/0157583to Ward et al, which is incorporated herein by reference in itsentirety. Further, in some embodiments the wire may define a variablecoil spacing, as described in U.S. Pat. App. Pub. No. 2014/0270730 toDePiano et al., which is incorporated herein by reference in itsentirety. Various embodiments of materials configured to produce heatwhen electrical current is applied therethrough may be employed to formthe heating element. Example materials from which the wire coil may beformed include titanium, platinum, silver, palladium, Kanthal (FeCrAl),Nichrome, Molybdenum disilicide (MoSi₂), molybdenum silicide (MoSi),Molybdenum disilicide doped with Aluminum (Mo(Si,Al)₂), graphite andgraphite-based materials; and ceramic (e.g., a positive or negativetemperature coefficient ceramic). The heating element may comprise awire defining a mesh, screen or lattice structure positioned about theliquid transport element. Example materials from which the wire mesh,screen, or lattice may be formed include titanium, platinum, silver,palladium, Kanthal (FeCrAl), Nichrome, Molybdenum disilicide (MoSi₂),molybdenum silicide (MoSi), Molybdenum disilicide doped with Aluminum(Mo(Si,Al)₂), graphite and graphite-based materials; and ceramic (e.g.,a positive or negative temperature coefficient ceramic). An exampleembodiment of a mesh heating element is disclosed in U.S. Pat. Appl.Pub. No. 2015/0034103 to Hon. In some embodiments, a stamped heatingelement may be employed in the atomizer, as described in U.S. Pat. Pub.No. 2014/0270729 to DePiano et al., which is incorporated herein byreference in its entirety. Further to the above, additionalrepresentative heating elements and materials for use therein aredescribed in U.S. Pat. No. 5,060,671 to Counts et al.; U.S. Pat. No.5,093,894 to Deevi et al.; U.S. Pat. No. 5,224,498 to Deevi et al.; U.S.Pat. No. 5,228,460 to Sprinkel Jr., et al.; U.S. Pat. No. 5,322,075 toDeevi et al.; U.S. Pat. No. 5,353,813 to Deevi et al.; U.S. Pat. No.5,468,936 to Deevi et al.; U.S. Pat. No. 5,498,850 to Das; U.S. Pat. No.5,659,656 to Das; U.S. Pat. No. 5,498,855 to Deevi et al.; U.S. Pat. No.5,530,225 to Hajaligol; U.S. Pat. No. 5,665,262 to Hajaligol; U.S. Pat.No. 5,573,692 to Das et al.; and U.S. Pat. No. 5,591,368 to Fleischhaueret al., the disclosures of which are incorporated herein by reference intheir entireties. Further, chemical heating may be employed in otherembodiments. Various additional examples of heaters and materialsemployed to form heaters are described in U.S. Pat. No. 8,881,737 toCollett et al., which is incorporated herein by reference, as notedabove.

A variety of heater components may be used in the present aerosoldelivery device. In various embodiments, one or more microheaters orlike solid state heaters may be used. Embodiments of microheaters andatomizers incorporating microheaters suitable for use in the presentlydisclosed devices are described in U.S. Pat. No. 8,881,737 to Collett etal., which is incorporated herein by reference in its entirety.

One or more heating terminals (e.g., positive and negative terminals)may connect to the heating element so as to form an electricalconnection with the power source and/or a terminal may connect to one ormore control elements of the aerosol delivery device. Further, variousexamples of electronic control components and functions performedthereby are described in U.S. Pat. App. Pub. No. 2014/0096781 to Searset al., which is incorporated herein by reference in its entirety.

Various components of an aerosol delivery device according to thepresent disclosure can be chosen from components described in the artand commercially available. Reference is made for example to thereservoir and heater system for controllable delivery of multipleaerosolizable materials in an electronic smoking article disclosed inU.S. Pat. App. Pub. No. 2014/0000638 to Sebastian et al., which isincorporated herein by reference in its entirety.

In further embodiments, one or more components of the aerosol deliverydevice may be formed from one or more carbon materials, which mayprovide advantages in terms of biodegradability and absence of wires. Inthis regard, the heating element may comprise carbon foam, the reservoirmay comprise carbonized fabric, and graphite may be employed to form anelectrical connection with the battery and controller. An exampleembodiment of a carbon-based cartridge is provided in U.S. Pat. App.Pub. No. 2013/0255702 to Griffith et al., which is incorporated hereinby reference in its entirety.

Aerosol delivery devices are often configured in a manner that mimicsaspects of certain traditional smoking devices such as cigarettes orcigars. In this regard, aerosol delivery devices typically define asubstantially cylindrical configuration. For example, aerosol deliverydevices often include a control body and a cartridge which attach in anend-to-end relationship to define the substantially cylindricalconfiguration. While such configurations may provide a look and feelthat is similar to traditional smoking articles, these configurationsmay suffer from certain detriments. For example,cylindrically-configured aerosol delivery devices may not defineattachment points usable to retain the aerosol delivery device in adesired position when not in use. Further, such configurations mayresult in a relatively large device when employed with reservoirs havingrelatively large capacity, resembling the size and shape of a cigar,which may not be suitable for temporary storage or transport in a user'spocket.

So-called “mod” devices may include configurations other than parallel,coaxial alignment of a control body and a cartridge. However, suchdevices may include exposed and/or poorly-supported electricalconnectors that connect the control body and cartridge, which may bestrained during use or storage, thereby potentially affecting theusability thereof. Accordingly, it may be desirable to provide aerosoldelivery devices in configurations and shapes that differ fromconfigurations and shapes associated with traditional smoking articlesand traditional aerosol delivery devices.

As such, embodiments of the present disclosure provide alternativeaerosol delivery devices configured to address the above-noteddeficiencies of existing configurations of aerosol delivery devicesand/or provide other benefits. FIG. 1 illustrates a side view of anaerosol delivery device 100 of the present disclosure. As illustrated,the aerosol delivery device 100 may include a control body 101, whichmay include a housing 102. In some embodiments the housing may comprisea plastic material, but various other materials, which are preferablysubstantially rigid, may be employed in other embodiments. The housing102 may be unitary or comprise multiple pieces. For example, the housing102 may include a body portion 102 a, which may itself comprise one ormore pieces, and an access door 102 b. As further illustrated in FIG. 1,the aerosol delivery device 100 may additionally include a cartridge200, which may be at least partially received in the control body 101.

FIG. 2 illustrates a partially-exploded sectional view through thecontrol body 101 of the aerosol delivery device 100. As illustrated, thehousing 102 may define an electrical power source cavity 104. Inparticular, the electrical power source cavity 104 may be defined in thebody portion 102 a of the housing 102. The electrical power sourcecavity 104 may be closed by, and accessed via, the access door 102 b. Asdescribed below, the electrical power source cavity 104 may beconfigured to receive an electrical power source.

Further, the housing 102 may define a cartridge cavity 106. As describedin detail below, the cartridge cavity 106 may be configured to receivethe cartridge 200 (see, e.g., FIG. 3). In this regard, the housing 102may define an external opening 108 at the cartridge cavity 106configured to receive the cartridge 200 therethrough.

The housing 102 may include a divider wall 107 that separates the powersource cavity 104 from the cartridge cavity 106. In some embodiments thedivider wall 107 completely separates the power source cavity 104 fromthe cartridge cavity 106. For example, the divider wall 107 may extendacross the length and thickness of the control body 101 such that thepower source cavity 104 and the cartridge cavity 106 are discretecavities. This configuration may be preferable in that it may preventfluid communication between the power source cavity 104 and thecartridge cavity 106. Thereby, for example, in the event of a structuralfailure of the electrical power source, chemical intrusion into thecartridge cavity 106 may be resisted. However, as may be understood, inother embodiments the divider wall may be discontinuous in one or bothof length and fitness. Such a configuration of the divider wall maystill respectively retain an electrical power source in the electricalpower source cavity and a cartridge in the cartridge cavity such thatthese components are securely retained in place.

The control body 101 may include one or more additional components. Thecomponents may be received in, or otherwise engaged with, the housing102. For example, the components may include an electrical circuit, theoperation of which is described below. The electrical circuit mayinclude a controller 110, first and second electrical contacts 112 a,112 b, and a coupler 114. In some embodiments the electrical circuit mayadditionally include an electronic display 116 (e.g., a liquid crystaldisplay). Further, the electrical circuit may include a flow sensor 118,which may be positioned at, or in fluid communication with, the coupler114. Wires or other electrical connectors may provide connectionsbetween the various components of the electrical circuit. In someembodiments the electrical circuit may further comprise a communicationmodule. The communication module may be configured to communicate viaBluetooth or any other communication standard. Examples of communicationmodules and related antenna components which may be included in theaerosol delivery device 100 are described in U.S. patent applicationSer. No. 14/802,789, filed Jul. 17, 2015, and Ser. No. 14/638,562, filedMar. 4, 2015, each to Marion et al.

FIG. 3 illustrates a sectional view through the aerosol delivery device100. As illustrated, the cartridge 200 may be at least partiallyreceived in the cartridge cavity 106 when engaged with the control body101. In this regard, the cartridge 200 may be inserted through theexternal opening 108 into the cartridge cavity 106. As the cartridge 200is inserted into the cartridge cavity 106, the cartridge 200 may engagethe coupler 114. Thereby, the cartridge 200 may establish an electricalconnection with the control circuit such that current may be selectivelydirected to the cartridge by the controller 110 to produce aerosol.

As further illustrated in FIG. 3, the aerosol delivery device 100 mayadditionally include an electrical power source 300. The electricalpower source 300 may be received in the electrical power source cavity104, and the access door 102 b may be secured to the body portion 102 aof the housing 102, such that the electrical power source 300 isretained in the electrical power source cavity 104. In this regard, theaerosol delivery device 100 may additionally include at least onefastener 120 (e.g., a screw) configured to retain the access door 102 bin engagement with the body portion 102 a of the housing 102.

When the electrical power source 300 is inserted into the electricalpower source cavity 104, the first electrical contact 112 a may engage afirst end of the electrical power source, at which a first terminal ofthe electrical power source may be positioned. Thereafter, when theaccess door 102 b is secured to the body portion 102, the secondelectrical contact 112 b may engage an opposing second end of theelectrical power source 300, at which a second terminal may bepositioned. Thereby, power from the electrical power source 300 may besupplied to the controller 110. However, as may be understood, theelectrical contacts 112 a, 112 b may be positioned and configured inother manners as appropriate for engagement with the terminals of theelectrical power source 300, such that various embodiments of theelectrical power source may be employed. For example, in anotherembodiment both of the electrical contacts may be positioned at andconfigured to engage either the top or the bottom of the electricalpower source.

In some embodiments the electrical power source 300 may further comprisea protective circuit. Such a protective circuit may prevent overchargingof the electrical power source and/or regulate the release of currentwithin acceptable limits. Further, the electrical power source mayadditionally include shock absorbing members (e.g., foam pads) in someembodiments, which may protect the electrical power source from damageassociated with dropping the aerosol delivery device 100.

As further illustrated in FIGS. 2 and 3, in some embodiments theelectrical power source cavity 104 and the cartridge cavity 106 may beelongated and respectively define a longitudinal axis 104 a, 106 a. Thelongitudinal axis 104 a of the electrical power source cavity 104 andthe longitudinal axis 106 a of the cartridge cavity 106 may besubstantially parallel to one another. Such a configuration may allowfor receipt of both the cartridge 200 and the electrical power source300 in a space efficient manner within the housing 102.

As noted herein, many existing embodiments of aerosol delivery devicesdefine generally elongated, tubular configurations wherein theelectrical power source and cartridge are positioned generally end toend to mimic the smoking articles such as cigarettes and cigars.Thereby, existing embodiments of aerosol delivery devices often includecartridges and aerosol delivery devices arranged with the longitudinalaxes thereof being parallel to one another. However, as illustrated inFIGS. 2 and 3, the aerosol delivery device 100 of the present disclosuremay be configured such that the longitudinal axis 104 a of theelectrical power source cavity 104 and the longitudinal axis 106 a ofthe cartridge cavity 106 are non-coaxial.

Configuring the electrical power source cavity 104 and the cartridgecavity 106 with parallel, but non-coaxial, longitudinal axes 104 a, 106a may provide numerous benefits. In this regard, the aerosol deliverydevice 100 may define a relatively shorter length due to the cartridge200 and the electrical power source 300 being positioned beside oneanother, instead of in an end-to-end relationship. Further, byconfiguring the electrical power source cavity 104 and the cartridgecavity 106 beside one another, the aerosol delivery device 100 maydefine an overall shape that is more suitable for transport in a user'spocket. Additionally, this configuration may allow the aerosol deliverydevice 100 to more easily fit in a user's hand. In this regard, a usermay more easily carry and use the aerosol delivery device in a concealedfashion within a palm of the user's hand due to the relatively shorterlength thereof, which may be desirable in certain social settings.

The side-by-side configuration may also provide a relatively largeinternal volume within the housing 102 suitable for receipt of thecomponents of the aerosol delivery device 100 in a number of variouspositions. By contrast, aerosol delivery devices arranged end-to-endhave limited options with respect to the positions of componentstherein, due to the reservoir in the cartridge and the electrical powersource in the control body typically defining cylindricalconfigurations. Thereby, any remaining space in the cartridge and thecontrol body is typically annular or cylindrical in shape, which is notsuitable for receipt of many components in a space efficient manner.Further, the relatively larger internal volume of the aerosol deliverydevice 100 of the present disclosure provided by the housing 102 mayaccommodate a relatively larger electrical power source 300 and/or arelatively larger cartridge 200, such that the respective electric andaerosol precursor composition storage capacities thereof may beincreased. Additionally, the relatively large internal volume of theaerosol delivery device 100 may accommodate various commerciallyavailable electrical power sources, rather than just custom electricalpower sources which may be required for cylindrical configurations, suchthat expenses associated with the components of the aerosol deliverydevice may be reduced.

The side-by-side configuration may additionally provide a relativelylarge exterior surface area. Further, the side-by-side configuration mayprovide relatively planar exterior surfaces (which may be slightlycurved for ergonomic or aesthetic purposes), which may be more suitablefor the display 116, as opposed to the sharply curved surfaces providedby a cylindrical aerosol delivery device. In this regard,commercially-available electronic displays typically define a planardisplay surface.

Thereby, for example, the electronic display 116 may be positioned at anumber of locations and may define a relatively larger size than anelectronic display on an aerosol delivery device defining a cylindricalconfiguration. In the illustrated embodiment the electronic display 116is positioned at a top of the body portion 102 a of the housing 102. Theexternal opening 108 to the cartridge cavity 106 may also be positionedat the top of the body portion 102 a of the housing. This position ofthe electronic display 116 may allow a user to view the electronicdisplay while the aerosol delivery device is grasped in the user's handin a manner suitable for taking a draw on the cartridge 200. In thisregard, the user's hand may extend around the sides of the aerosoldelivery device, such that the top surface of the aerosol deliverydevice, at which the electronic display 116 and the exposed portion ofthe cartridge 200 are positioned, is exposed and uncovered by the user'shand. Thus, various information regarding the aerosol delivery device100 may be easily viewed during normal usage. For example, the datadisplayed by the electronic display 116 may include a remainingcartridge aerosol precursor composition level, a remaining power sourcelevel, historical usage information, heat and aerosol output settings, acharging status, a communication status (e.g., when linked to anotherdevice via Bluetooth or other communication protocol), the time, and/orvarious other data.

The side-by-side configuration of the aerosol delivery device 100 of thepresent disclosure may provide additional benefits. For example, thecartridge 200 may engage the control body 101 in a manner that mayprovide for a secure connection therebetween, which may reduce stressand strain thereon as compared to embodiments of aerosol deliverydevices in which the connection between the cartridge and control bodyis exposed (e.g. in embodiments in which the cartridge and the controlbody are arranged end-to-end). In this regard, the coupler 114 may berecessed in or proximate the cartridge cavity 106 such that the housing102 protects the connection between the cartridge 200 and the controlbody 101. Further, a portion, and more preferably a majority, of thelongitudinal length of the cartridge 200 may be retained in thecartridge cavity 106 and the size and shape of the cartridge cavity maysubstantially correspond to that of the cartridge, such that the housing102 may resist movement of the cartridge, rather than the coupler 114bearing the entirety of such stress and strain associated with forcesapplied to one or both of the cartridge and the control body 101. Inthis regard, in aerosol delivery devices configured with a control bodyand a cartridge arranged end-to-end, the connection between thecartridge and the control body may bear all or substantially all of thestress and strain associated with force applied to one or both of thecartridge and the control body. Such stress and strain may damage theconnection therebetween, which can impede operation thereof, due to theconnection including an electrical connection that supplies current tothe cartridge for vaporization purposes. Further, although “mod” devicesmay define configurations other than the end-to-end configurationdescribed above, such devices often include exposed electricalconnectors that are subject to stress and strain. Accordingly, theside-by side, parallel but non-coaxial configuration of the electricpower source cavity 104 and the cartridge cavity 106 of the aerosoldelivery device 100 of the present disclosure may provide variousbenefits.

Various embodiments of the cartridge 200 may be employed in the aerosoldelivery device 100. In this regard, a side view of the cartridge 200,rather than a sectional view therethrough, is illustrated in FIG. 3 inlight of the various possible configurations of the components of thecartridge. However, one example embodiment of the cartridge isillustrated in FIG. 4.

As illustrated in FIG. 4, the cartridge 200′ may comprise a baseshipping plug 202′, a base 204′, a control component terminal 206′, anelectronic control component 208′, a flow director 210′, an atomizer212′, a reservoir substrate 214′, an outer body 216′, a label 218′, amouthpiece 220′, and a mouthpiece shipping plug 222′ according to anexample embodiment of the present disclosure. The base 204′ may becoupled to a first end of the outer body 216′ and the mouthpiece 220′may be coupled to an opposing second end of the outer body to at leastpartially enclose the remaining components of the cartridge 200′therein, with the exception of the label 218′, the mouthpiece shippingplug 222′, and the base shipping plug 202′. The base 204′ may beconfigured to engage the coupler 114. In some embodiments the base 204′may comprise anti-rotation features that substantially prevent relativerotation between the cartridge and associated device including a powersource as disclosed in U.S. Pat. App. Pub. No. 2014/0261495 to Novak etal., which is incorporated herein by reference in its entirety.

The base shipping plug 202′ may be configured to engage and protect thebase 204′ prior to use of the cartridge 200′. Similarly, the mouthpieceshipping plug 222′ may be configured to engage and protect themouthpiece 220′ prior to use of the cartridge 200′. The controlcomponent terminal 206′, the electronic control component 208′, the flowdirector 210′, the atomizer 212′, and the reservoir substrate 214′ maybe retained within the outer body 216′. The label 218′ may at leastpartially surround the outer body 216′ and include information such as aproduct identifier thereon.

The atomizer 212′ may comprise a first heating terminal 234 a′ and asecond heating terminal 234 b′, a liquid transport element 238′, and aheating element 240′. In this regard, the reservoir substrate 214′ maybe configured to hold an aerosol precursor composition. The reservoirsubstrate 214′ is in fluid connection with the liquid transport element238′ so as to transport the aerosol precursor composition from thereservoir substrate 214′ to the heating element 240′ (e.g., viacapillary action). Thereby, when current is directed to the heatingelement 240′ via the heating terminals 234 a′, 234 b′, the aerosolprecursor composition may be vaporized.

Various other details with respect to the components that may beincluded in the cartridge 200′, are provided, for example, in U.S. Pat.App. Pub. No. 2014/0261495 to Novak et al., which is incorporated hereinby reference in its entirety. In this regard, FIG. 7 thereof illustratesan enlarged exploded view of a base and a control component terminal;FIG. 8 thereof illustrates an enlarged perspective view of the base andthe control component terminal in an assembled configuration; FIG. 9thereof illustrates an enlarged perspective view of the base, thecontrol component terminal, an electronic control component, and heatingterminals of an atomizer in an assembled configuration; FIG. 10 thereofillustrates an enlarged perspective view of the base, the atomizer, andthe control component in an assembled configuration; FIG. 11 thereofillustrates an opposing perspective view of the assembly of FIG. 10thereof; FIG. 12 thereof illustrates an enlarged perspective view of thebase, the atomizer, the flow director, and the reservoir substrate in anassembled configuration; FIG. 13 thereof illustrates a perspective viewof the base and an outer body in an assembled configuration; FIG. 14thereof illustrates a perspective view of a cartridge in an assembledconfiguration; FIG. 15 thereof illustrates a first partial perspectiveview of the cartridge of FIG. 14 thereof and a coupler for a controlbody; FIG. 16 thereof illustrates an opposing second partial perspectiveview of the cartridge of FIG. 14 thereof and the coupler of FIG. 11thereof; FIG. 17 thereof illustrates a perspective view of a cartridgeincluding a base with an anti-rotation mechanism; FIG. 18 thereofillustrates a perspective view of a control body including a couplerwith an anti-rotation mechanism; FIG. 19 thereof illustrates alignmentof the cartridge of FIG. 17 with the control body of FIG. 18; FIG. 20thereof illustrates an aerosol delivery device comprising the cartridgeof FIG. 17 thereof and the control body of FIG. 18 thereof with amodified view through the aerosol delivery device illustrating theengagement of the anti-rotation mechanism of the cartridge with theanti-rotation mechanism of the connector body; FIG. 21 thereofillustrates a perspective view of a base with an anti-rotationmechanism; FIG. 22 thereof illustrates a perspective view of a couplerwith an anti-rotation mechanism; and FIG. 23 thereof illustrates asectional view through the base of FIG. 21 thereof and the coupler ofFIG. 22 thereof in an engaged configuration.

In another embodiment the cartridge 200 may be substantially similar, oridentical, to the cartridge disclosed in U.S. patent application Ser.No. 14/286,552 to Brinkley et al., filed May 23, 2014, which isincorporated herein by reference in its entirety. Thus, for example, thecartridge may include a flow director defining a non-tubularconfiguration, an electronics compartment sealed with respect to areservoir compartment, and/or any of the various other features andcomponents disclosed therein. Accordingly, it should be understood thatthe particular embodiments of the cartridge 200 described herein isprovided for example purposes only.

In this regard, a sectional view through an additional embodiment of thecartridge 200 is illustrated in FIG. 5. As illustrated, the cartridge200″ may include a base 204″, a control component terminal 206″, anelectronic control component 208″, a flow director 210″ which may bedefined by an outer body 216″ or a separate component, an atomizer 212″,and a mouthpiece 220″ according to an example embodiment of the presentdisclosure. The atomizer 212″ may comprise a first heating terminal 234a″ and a second heating terminal 234 b″, a liquid transport element 238″and a heating element 240″. The cartridge 200″ may additionally includea base shipping plug, a label, and a mouthpiece shipping plug, asdescribed above.

The base 204″ may be coupled to a first end of the outer body 216″ andthe mouthpiece 220″ may be coupled to an opposing second end of theouter body to at least partially enclose the remaining components of thecartridge 200″ therein. In some embodiments the base 204″ may compriseanti-rotation features that substantially prevent relative rotationbetween the cartridge and associated device including a power source asdisclosed in U.S. Pat. App. Pub. No. 2014/0261495 to Novak et al., whichis incorporated herein by reference in its entirety.

The cartridge 200″ may further comprise a sealing member 242″ and aninitial liquid transport element 244″. In this regard, the outer body216″ and/or an additional component may be configured to hold an aerosolprecursor composition 246″ in a reservoir 248″. In some embodiments thereservoir 248″ may be configured to be refillable, whereas in otherembodiments the cartridge 200″ may be configured for a single use. Thesealing member 242″ may be positioned at an end of the chamber 248″ andinclude one or more apertures 250″ that allow the aerosol precursorcomposition 246″ to contact the initial liquid transport element 244″.Further, the liquid transport element 238″ of the atomizer 212″ may bein contact with the initial liquid transport element 244″. Both theinitial liquid transport element 244″ and the liquid transport element238″ of the atomizer 212″ may comprise wicking and/or porous materialsthat allow movement of the aerosol precursor composition 246″therethrough (e.g., via capillary action), such that the aerosolprecursor composition may be drawn to the heating element 240″ andheated and vaporized when current is applied to the heating element viathe heating terminals 234 a″, 234 b″ by the controller 110 of thecontrol body 101 (see, e.g., FIG. 6).

FIG. 6 illustrates the aerosol delivery device 100 when the electricalpower source 300 is received in the electrical power source cavity 104,and the cartridge 200″ of FIG. 5 is received in the cartridge cavity106. As illustrated, in some embodiments, the electrical circuit mayadditionally include an illumination source 122 such as a light emittingdiode (LED). Further, the control body 101 may include an illuminationsource cover 124, which may cover, protect, and/or conceal theillumination source 122. The illumination source cover 124 may betranslucent or transparent such that light emitted by the illuminationsource may travel therethrough. In some embodiments the illuminationsource cover 124 may be tinted or diffuse such that the presence of theillumination source is hidden or obscured when not in use.

As further illustrated in FIG. 6, in some embodiments the cartridge 200″may include a viewing window 252″, which may allow a user to view aquantity of the aerosol precursor composition 246″ remaining in thereservoir 248″. For example, all or a portion of the outer body 216″ ofthe cartridge 200″ may comprise a translucent or transparent material.The illumination source 122 and the illumination source cover 124 may bepositioned in the body portion 102 a of the housing 102 at the cartridgecavity 106 at a position that aligns with the viewing window 252″ suchthat light produced by the illumination source may be directed into thecartridge 200″ to facilitate viewing of the level of the aerosolprecursor composition 246″. In this regard, the body portion 102 a ofthe housing 102 may include a cutout or other feature defining a viewingopening 126. Thereby, the user may be able to see the level of theaerosol precursor composition 246″ through the viewing opening 126.

The controller 110 may direct the illumination source 122 to outputlight under certain circumstances, such as after a draw on the cartridge200″ is detected. The illumination source 122 may additionally oralternatively output light when a separate actuator (e.g., a button) isdepressed or otherwise actuated. Accordingly, a user may be keptapprised of a level of the aerosol precursor composition in thecartridge 200″.

Note that inclusion of the illumination source 122 is optional. In thisregard, ambient light be sufficient for viewing the level of the aerosolprecursor composition 246″ through the viewing opening 126 in someembodiments. However, inclusion of the illumination source 122 may bepreferable due to increased usability in low-light situations.

The controller 110 may be configured to control one or more operationsof the aerosol delivery device 100. The controller 110 may verify thatthe cartridge 200 is authentic using information provided by the controlcomponent 208′, 208″. Usage of the cartridge 200 may be allowed only ifthe cartridge is determined to be authentic. Further, when a user drawson the cartridge 200, the flow sensor 118 (e.g. a pressure sensor) maydetect the draw. In response, the controller 110 may direct current tothe cartridge 200 such that that the heating element 240′, 240″ producesheat and vaporizes the aerosol precursor composition, which may bedirected to the user. In addition, the aerosol delivery device mayinclude an actuator that may be manually actuated to trigger thecontroller to direct current to the cartridge 200. The actuator may beused in lieu of the flow sensor 118, or to provide supplemental powerfrom the electrical power source to the cartridge to change (e.g.,increase) the aerosol output of the aerosol delivery device. In otherembodiments the actuator may be used in conjunction with the controllerto adjust the amount of power directed from the electrical power sourceto the cartridge, such that the aerosol delivery device may have variousaerosol output settings (e.g., aerosol mass output settings).Accordingly the actuator (e.g., a button or button assembly) may beconfigured to control a power output level directed from the electricalpower source to the cartridge.

In some embodiments the actuator (e.g., button or button assembly) mayhave selective regions or a plurality of regions such as a lower region,a middle region, and an upper region. Each region of the actuator may beconfigured to direct a differing level of power (e.g., current and/orvoltage) a from the electrical power source to the cartridge. Thereby,the differing regions of the actuator may each correspond to a differingaerosol output setting. The actuator may include one or a plurality ofsensors (e.g., pressure and/or force sensors) at each region such thatthe force applied to the actuator by the user at one or more of theregions may be detected to control the output of the aerosol viadiffering selectable power output levels directed from the electricalpower source to the cartridge. Accordingly, the power output level maybe controlled based on a location at which the actuator is actuated.Alternatively or additionally, the power output level may be controlledbased on the amount of force applied to the actuator, which may bedetermined via a force sensor (e.g., a stress or strain sensor).

As may be understood, the exact shape and dimensions of the aerosoldelivery device 100 may vary. In this regard, FIGS. 7-10 illustrate analternate embodiment of the control body 101′, wherein only thosedifferences with respect to the control body 101 described above arenoted. Thus, each of the aerosol delivery devices may include some orall of the components and features described herein in any combination,unless otherwise noted.

As illustrated in FIG. 7, the control body 101′ may define a morerounded profile for improved ergonomics. As further illustrated in FIG.7, the control body 101′ may further comprise an indicator 128′. Theindicator 128′ may output light to indicate an operational status of thecontrol body. In some embodiments the indicator 128′ may be used tocommunicate the operational status of the device without usage of theelectronic display surface 116′. For instance, the indicator 128′ mayflash or change colors when the cartridge is low in aerosol precursorcomposition or to indicate the electrical power source needs rechargingor replacement. In addition, the indicator 128′ may light up when theflow sensor detects a puff on the cartridge.

In some embodiments the indicator 128′ may be configured to illuminatewith one or more of a plurality of colors, durations, frequencies,and/or intensities to indicate to the user certain conditions of theaerosol delivery device such as the power output level, the status ofthe electrical power source, and/or the activated or inactivated stateof the aerosol delivery device which correspond to the output of theindicator. Thereby, the indicator 128′ may include an illuminationsource that activates with one or more of a plurality of colors,durations, frequencies, and/or intensities to indicate to the usercertain conditions of the aerosol delivery device such as the poweroutput level, the status of the power source, and/or the activated orinactivated state of the aerosol delivery device. The indicator 128′ maybe configurable by the user to control the color or colors of theillumination source and/or other output parameters thereof. Further, theuser may be able to control which device status value is communicated tothe user by the illumination signal.

As additionally illustrated in FIG. 7, the body portion 102 a′ of thehousing 102′ may include a side opening 130′. The side opening 130′ maybe configured to engage an outer cover 132′ (e.g., via interferencefit), which is illustrated in FIG. 8. Thereby, the outer cover 132′ maybe engaged with an exterior of the housing 102′. In some embodiments theouter cover 132′ may comprise silicon, which may provide enhanced gripsuch that it is easier to retain the control body 101′ in the handwithout dropping it. However, various other materials (e.g., otherrubbers), which may be textured or smooth, may be employed in otherembodiments. Use of a resilient outer cover 132′ may provide variousother benefits. For example, in one embodiment, depression of the outercover 132′ at the side opening 130′ may trigger the illumination source122 (e.g., via actuation of an actuator) to illuminate the fluid levelin the cartridge 200. In another embodiment, the depression of the outercover 132′ at the side opening 130′ may trigger the illumination source122, where the duration of the depression of the outer cover correspondsto the duration of the activation of the illumination source, such thatthe user may continuously illuminate the cartridge 200 for a desiredduration during filling or refilling of the cartridge or when otherwisedesired for a user-selected period of time.

FIG. 9 illustrates a partial side view of the control body 101′. Asillustrated, the illumination source cover 124′ may be aligned with theviewing opening 126′ as described above. In this illustrated embodiment,the viewing opening 126′ may be relatively wide so as to facilitateviewing of the level of the aerosol precursor composition in thecartridge. For example, the viewing opening 126′ may define an openingwith a width perpendicular to the longitudinal axis 106 a′ of thecartridge cavity 106′ that is equal to at least half of a diameter ofthe cartridge in some embodiments.

As noted above, in some embodiments the body portion of the housing ofthe control body may comprise multiple pieces. In this regard, FIG. 10illustrates a first section 102 a 1′ of the body portion 102 a′ of thehousing 102′ (see, FIG. 7). A second section 102 a 2′ and a thirdsection 102 a 3′ of the body portion 102 a′ of the housing 102′ areillustrated in FIG. 7. The third section 102 a 3′ may be integral withthe section 102 a 2′, or a separate component. The first and secondsections 102 a 1′, 102 a 2′ of the body portion 102′ of the housing 102′may be configured to engage the access door 102 b′ (see, FIG. 10). Theelectronic display 116′ may be positioned at (e.g., under) the thirdsection 102 a 3′ of the body portion 102 a′ of the housing 102′. In thisregard, all or a portion of the housing 102′ may be translucent ortransparent in some embodiments. The housing 102′ may additionallyinclude an illumination source or have an illumination source inproximity thereto. For example, the housing 102′ may include theillumination source 122 described above, which may be configured to emitdirect or indirect illumination through the housing 102′ where thehousing may be translucent or transparent.

As illustrated in FIG. 10, the first section 102 a 1′ of the bodyportion 102 a′ of the housing 102′ may additionally include a sideopening 134′ configured to engage the outer cover 132′ (see, e.g., FIG.8). Thereby, the outer cover 132′ may be firmly held in place via theopposing side openings 130′, 134′. Whereas the outer body 132′ mayprovide enhanced grip, the third section 102 a′ may comprise a metalsuch as aluminum for enhanced strength and/or improved cosmeticappearance, or a separate outer body defining such characteristics maybe attached to the third section.

FIG. 10 further illustrates an inside of the first section 102 a 1′ ofthe body portion 102 a′ of the housing 102′. As illustrated, the housing102′ may define one or more ribs 136′, which may be configured to retainthe electric power source 300 (see, e.g., FIG. 3) within the electricalpower source cavity 104′ and/or retain the cartridge 200 (see, e.g.,FIG. 3) in the cartridge cavity 106′. In this regard, the ribs 136′ maybe curved or otherwise tailored to match the size and shape of theelectric power source 300 and/or the cartridge 200. The ribs 136′ mayextend to an end portion 138′. The end portions 138′ of the ribs 136′ atthe first section 102 a 1′ of the body portion 102 a′ of the housing102′ may be configured to engage corresponding end portions of the ribsat the second section 102 a 2′ (see, FIG. 7) of the body portion of thehousing so as to separate the electrical power source cavity 104′ fromthe cartridge cavity 106′ to retain the electrical power source 300 andthe cartridge 200 (see, FIG. 3) respectively therein. In this regard,the end portions 138′ of the ribs 136′ may collectively define a dividerwall 107′ that is segmented along the length thereof. Usage of the ribs136′, rather than a solid structure, may reduce the quantity of materialrequired to form the housing 102′, thereby additionally reducing theweight of the housing while still retaining the components of thecontrol body 101′ in the desired positions and providing addedstiffness. The ribs 136′ may comprise a non-rigid material such as foamor a thermoplastic polymer or include an element comprising foam,thermoplastic polymer, or other non-rigid material that allows the ribs136′ to compress or displace in the event that the electrical powersource 300 undergoes changes in diameter such that can occur withdiametric swelling that is common with lithium-type batteries. In thisregard, the ribs 136′ may at least partially surround the electricalpower source 300 (see, e.g., FIG. 3).

As additionally illustrated in FIG. 10, the first section 102 a 1′ ofthe body portion 102 a′ of the housing 102′ may include protrusionsand/or receptacles 140′, which may be configured to engage correspondingreceptacles/protrusions at the second section 102 a 2′ (see, FIG. 7).Thereby, the sections 102 a 1′, 102 a 2′ of the housing 102′ mayinterlock with one another when assembled.

As illustrated in FIG. 10, section 102 b′ may include an orifice 137′ orplurality of orifices in fluid communication with the electrical powersource cavity 104′ and the atmosphere outside of the housing 102′ toallow for the escape of any gas or gases that may be produced by theelectrical power source 300 (see, e.g., FIG. 3) to prevent the gas orgases from generating a region of increased pressure within the housing102′. The orifice 137′ may comprise one or more openings of sufficientcross sectional area as to prevent a pressure differential between theinternal region of the housing 102′ and the outside atmosphere. In oneembodiment the orifice 137′ may include a permeable membrane or porousmaterial that allows gas or gases that may be produced by the electricalpower source 300 (see, e.g., FIG. 3) to escape to the outside atmospherewhile preventing the entrance of liquid into the housing 102′ due to theselective permeability of the membrane or porous material.

FIGS. 11-15 illustrate an additional embodiment of the control body101″. The control body 101″ may be substantially similar to the controlbody 101′ of FIGS. 7-10 in one or more respects. In this regard, asillustrated in FIGS. 11 and 12, the control body 101″ may include ahousing 102″ comprising a body portion 102 a″ and an access door 102 b″which may be secured to the body portion via a screw 120″ (see, FIG.13). The body portion 102 a″ may include multiple sections includingfirst and second sections 102 a 1″, 102 a 2″. The first section 102 a 1″may define protrusions and/or receptacles 140″ configured to engagecorresponding receptacles/protrusions at the second section 102 a 2′(see, FIG. 7). The body portion 102 a″ may define one or more ribs 136″that respectively extend to an end portion 138″ to define a dividingwall 107″. As illustrated the ribs 136″ may extend in both the powersource cavity 104″ and the cartridge cavity 106″ in some embodiments tothereby assist in respectively retaining the electrical power source andthe cartridge therein. Further, the control body 101″ may include theindicator 128″ and an outer cover 132″ (see, FIG. 14). The electronicdisplay 116″ may be positioned at the top of the housing 102″ proximatethe opening to the external opening 108″ to the cartridge cavity 106″,which extends along the longitudinal axis 106 a″.

However, the control body 101″ may differ in one or more respects fromthe control bodies described above. In this regard, in addition to theend portions 138″ of the ribs 136″, the dividing wall 107″ mayadditionally include a partial wall 109″, which further assists inretaining a cartridge in the cartridge cavity 106″. Further, asillustrated in FIGS. 11 and 12, in some embodiments the body portion 102a″ of the housing 102″ may include first and second side openings 130a″, 130 b″ at the first section 102 a 1″ and first and second sideopenings 134 a″, 134 b″ at the second section 102 a 2″ thereof (see,FIGS. 11 and 13). Usage of multiple side openings 130 a″, 130 b″, 134a″, 134 b″ at each section 102 a 1″, 102 a 2″ of the body portion 102 a″of the housing 102″ may provide for improved engagement of the outercover 132″ therewith, as illustrated in FIG. 12.

Further, as illustrated in FIG. 15, and as noted above, in someembodiments the viewing opening 126′ may be relatively wide (see e.g.,FIG. 9). However, as illustrated in FIG. 13, in other embodiments theviewing opening 126″ may be relatively less wide. For example, theviewing opening may define a width that is equal to less than half of adiameter of the configured to be received in the cartridge compartment106″ in some embodiments. Whereas a wide viewing opening may facilitateviewing of the level of the aerosol precursor composition, a relativelyless wide viewing opening may provide more protection to the cartridge,while still allowing a user to view the level of the aerosol precursorcomposition.

In an additional embodiment, FIG. 16 illustrates a method for assemblingan aerosol delivery. As illustrated, the method may include providing ahousing at operation 402. The housing may define an electrical powersource cavity configured to receive an electrical power source and acartridge cavity configured to receive a cartridge including an aerosolprecursor composition. The electrical power source cavity and thecartridge cavity may be elongated and respectively define a longitudinalaxis. The longitudinal axis of the electrical power source cavity andthe longitudinal axis of the cartridge cavity may be non-coaxial andoriented substantially parallel to one another. Further, the method mayinclude positioning an electrical contact in the electrical power sourcecavity, the electrical contact being configured to engage the electricalpower source at operation 404. Additionally, the method may includepositioning a coupler in the cartridge cavity, the coupler beingconfigured to engage the cartridge at operation 406.

In some embodiments the method may further comprise inserting theelectrical power source in the electrical power source cavity andengaging the electrical power source with the electrical contact. Themethod may additionally include inserting the cartridge into thecartridge cavity and engaging the cartridge with the coupler. Insertingthe cartridge into the cartridge cavity may include inserting thecartridge through an external opening defined by the housing.

Providing the housing at operating 402 may include defining a viewingopening at the cartridge cavity. Further, the method may includeengaging an outer cover with an exterior of the housing. The method mayadditionally include positioning an illumination source in the housing.The illumination source may be configured to illuminate the cartridge inthe cartridge cavity. The method may further include engaging anelectronic display with the housing. Providing the housing at operation402 may include engaging a first body portion with a second bodyportion. Providing the housing at operation 402 may further includeengaging an access door with at least one of the first body portion andthe second body portion, the access door being configured to selectivelyprovide access to the electrical power source cavity.

An additional embodiment of an aerosol delivery device 500 isillustrated in FIG. 17. As illustrated the aerosol delivery device 500may include a control body 501 and a cartridge. In the illustratedembodiment the cartridge 200″ from FIG. 5 is included in the aerosoldelivery device 500. However, as may be understood, other cartridges maybe employed in other embodiments.

The control body 501 may include a housing 502. The housing 502 may beintegral or comprise a plurality of pieces. For example, the housing 502may include an electrical power source portion 502 a, an access door 502b, and a coupler portion 502 c. Access door 502 b may include an orificeor plurality of orifices in fluid communication with the atmosphereoutside of the housing 502 b to allow for the escape of any gas or gasesthat may be produced by electrical power source 504 (see, FIG. 18) toprevent the gas or gases from generating a region of increased pressurewithin the housing 502 as described above with respect to the orifice137 in FIG. 10. In this regard, each of the housings of the aerosoldelivery devices of the present disclosure may include such an orifice.The orifice may preferably be located at an access door to conceal theorifice and position the orifice at the electrical power source cavity,but the orifice may be located at other positions in other embodiments.

In this regard, FIG. 18 illustrates a partial exploded view of thecontrol body 501. As illustrated, the electrical power source portion502 a of the housing 502 may include a first body portion 502 a 1 and asecond body portion 502 a 2. The first body portion 502 a 1 and thesecond body portion 502 a 2 may be configured to engage one another anddefine an electrical power source cavity 504. The electrical powersource cavity 504 may be configured to receive an electrical powersource 600 (e.g., a battery and/or a capacitor). The electrical powersource cavity 504 may define a first longitudinal axis 504 a.

Further, the coupler portion 502 c of the housing 502 may be configuredto engage the electrical power source portion 502 a of the housing. Acoupler 514 may be engaged with the coupler portion 502 c of the housing502. For example, the coupler 514 may be positioned at least partiallywithin the coupler portion 502 c of the housing 502.

The coupler 514 may be configured to engage the cartridge 200″ (see,FIG. 17), which may include an aerosol precursor composition. Whenengaged with the coupler 514, the cartridge 200″ may extend along asecond longitudinal axis 200 a″, as illustrated in FIG. 17. The firstlongitudinal axis 504 a, which is defined by the electrical power sourcecavity 504, and the second longitudinal axis 200 a″, which is defined bythe cartridge 200″, may be non-coaxial and oriented substantiallyparallel to one another. This configuration may provide various benefitsas noted above with respect to embodiments of control bodies wherein thelongitudinal axis of the electrical power source cavity and thelongitudinal axis of the cartridge cavity are non-coaxial butsubstantially parallel.

In some embodiments the cartridge 200″ may be at least partiallyreceived in a coupler cavity 506 defined by the coupler portion 502 c ofthe housing 502. In this regard, as noted above, the coupler 514 may beat least partially received in the coupler cavity 506. Thereby, a depthof the coupler cavity 506 as well as the position of the coupler 514(see, FIG. 18) therein may determine whether or not the cartridge 200″is at least partially received in the coupler cavity 506. Partiallyreceiving the cartridge 200″ in the coupler cavity 506 may provide forimproved engagement of the cartridge with the control body 501 and/orreduce the susceptibility of damage or contamination to the coupler 514.However, in other embodiments the cartridge 200″ may not extend into thecoupler portion 502 c of the housing 502. This configuration mayfacilitate engagement of the cartridge 200″ with the coupler 514 andallow for usage of a wider variety of shapes and sizes of cartridgeswith the control body 501.

The control body 501 may additionally include a controller 510 (see,e.g., FIG. 20), which is not shown in FIG. 18 for clarity purposes. Thecontroller 510 may comprise a control board in some embodiments. Thecontroller 510 may be configured to control some or all of the functionsof the control body 501 including directing current from the electricalpower source 600 to the cartridge 200″. In this regard, the controller510 may be electrically coupled to the electrical power source 600.

As illustrated in FIG. 18, the control body 501 may additionally includeone or more button assemblies. In particular, the control body 501 mayinclude a first button assembly 542 and second button assembly 544. Asillustrated in FIG. 19, the first button assembly 542 may be configuredto actuate a first switch 546 on the controller 510. Similarly, thesecond button assembly 544 may be configured to actuate a second switch548 on the controller 510. In this regard, the button assemblies 542,544 may be configured to bend or otherwise move to actuate the switches546, 548. By way of example, the first button assembly 542 and thesecond button assembly 544 may be hingedly coupled to one or both of thefirst body portion 502 a 1 and the second body portion 502 a 2 (see,e.g., FIG. 18) of the electrical power source portion 502 a of thehousing 502.

Thereby, actuation of the switches 546, 548 may control one or morefunctions of the control body 501. For example, actuation of the firstswitch 546 may direct current from the electrical power source 600 tothe cartridge 200″ (see, FIG. 17) to heat an aerosol precursorcomposition therein and produce an aerosol. Further, actuation of thesecond switch 548 may control other functions.

By way of example, the control body 501 may further comprise anillumination source 522 such as a light emitting diode (LED). Theillumination source 522 may be configured to output illumination. Inthis regard, the control body 501 may include an illumination sourcecover 524, which may cover, protect, and/or conceal the illuminationsource 522. The illumination source cover 524 may be translucent ortransparent such that light emitted by the illumination source maytravel therethrough. In some embodiments the illumination source cover524 may be tinted or diffuse such that the presence of the illuminationsource 522 is hidden or obscured when not in use.

The illumination source 522 may be configured to illuminate thecartridge 200″. In particular, as schematically illustrated in FIG. 17,the cartridge 200″ may include the viewing window 252″ such that a levelof the aerosol precursor therein may be viewed as described above.Accordingly, the second button assembly 544 may be employed to turn onthe illumination source 522 such that illumination is directed throughthe viewing window 252″ of the cartridge 200″ and thereby a user maymore easily view a level of aerosol precursor composition therein,and/or the second switch may perform other functions. For example, inanother embodiment depression of the second button assembly 544, andthereby actuation of the second switch 548, may cause the controller 510to provide supplemental power from the electrical power source to thecartridge to increase the aerosol output of the aerosol delivery device,or to direct power to the cartridge, regardless of whether a draw on thecartridge is detected. In this regard, in some embodiments the aerosoldelivery device may not include a flow sensor. In other embodiments thesecond button assembly 544 may be used to actuate the second switch 548to cycle through various adjustable controller power levels, such thatthe device may have various aerosol mass output settings, or variousother functions may be controlled. Accordingly, the second buttonassembly 544 and/or any of the other actuators discussed herein may beconfigured to control a power output level directed from the electricalpower source to the cartridge and/or otherwise control a quantity (e.g.,mass) of aerosol outputted.

In some embodiments the second button assembly 544 may at leastpartially define a dividing wall 550 that separates the cartridge 200″from the electrical power source cavity 504 (see, FIG. 18). Further, asdescribed below, the controller 510 may be received in the electricalpower source cavity 504. Thereby, the second button assembly 544 mayinclude the illumination source cover 524 at the dividing wall 550 suchthat the illumination may be directed therethrough to the cartridge200″.

Assembly of the control body 501 may be performed in various manners. Inone embodiment the controller 510 may be at least partially wrappedabout the electrical power source 600, as illustrated in FIG. 20. Forexample, the controller 510 may be bent or configured such that thepower source 600 is received between opposing substantially parallelwalls of the controller. The controller 510 may be electricallyconnected to the electrical power source 600 at this time as well. Inthis regard, by way of example, the electrical power source may includewires or other electrical leads that are soldered or otherwise connectedto the controller 510.

As illustrated in FIG. 21, the controller 510 and the electrical powersource 600 may be inserted into the housing 502. More particularly, thecontroller 510 and the electrical power source may be received in theelectrical power source cavity 504. In some embodiments the housing 500may include features configured to engage the controller 510. Forexample, as illustrated, the controller 510 may be received in a slot552 which may be defined by an extension 554 formed by the first bodyportion 502 a 1 of the electrical power source portion 502 a of thehousing 502. Thereby, the extension 554 may support the controller 510to allow for actuation of the switches 546, 548 in the manner describedabove.

In one embodiment the first button assembly 542 may be engaged with thefirst body portion 502 a 1 of the electrical power source portion 502 aof the housing 502 before the controller 510 and the electrical powersource 600 are inserted into the electrical power source cavity 504. Forexample, a portion of the first button assembly 542 may be welded (e.g.,ultrasonic welded), adhered, engaged via interference fit, ormechanically coupled to the first body portion 502 a 1 of the electricalpower source portion 502 a of the housing 502. Thereby, the first buttonassembly 542 may be engaged with the first body portion 502 a 1, butstill able to move to actuate the first switch 546 as described above.Additionally, as further illustrated in FIG. 21, in some embodiments thesecond button assembly 544 may be engaged with the first body portion502 a 1 of the electrical power source portion 502 a of the housing 502before the controller 510 and the electrical power source 600 areinserted into the electrical power source cavity 504. For example, aportion of the second button assembly 544 may be welded (e.g.,ultrasonic welded), adhered, engaged via interference fit, ormechanically coupled to the first body portion 502 a 1 of the electricalpower source portion 502 a of the housing 502. Thereby, the secondbutton assembly 544 may be engaged with the first body portion 502 a 1,but still able to move to actuate the second switch 546 as describedabove.

Returning to FIG. 20, the controller 510 may include a connector 556.The connector 556 may comprise an electrical connector and/or a dataconnector. Thereby, the connector 556 may be employed to recharge theelectrical power source 600 and/or transmit data to or from thecontroller 510. As illustrated in FIG. 21, the housing 502 may include arecess 558 configured to receive the connector 556. For example, therecess 558 may be defined by one or both of the first body portion 502 a1 and the second body portion 502 a 2 of the electrical power sourceportion 502 a of the housing 502.

As illustrated in FIG. 22, the second body portion 502 a 2 of theelectrical power source portion 502 a of the housing 502 may be engagedwith the first body portion 502 a 1 after the controller 510 and theelectrical power source 600 are inserted into the electrical powersource cavity 504. For example, the second body portion 502 a 2 may bewelded (e.g., ultrasonic welded), adhered, engaged via interference fit,or mechanically coupled to the first body portion 502 a 1 of theelectrical power source portion 502 a of the housing 502. Further, thecoupler portion 502 c of the housing 502 may be engaged with theelectrical power source portion 502 a of the housing 502. For example,the coupler portion 502 c may be welded (e.g., ultrasonic welded),adhered, engaged via interference fit, or mechanically coupled to theelectrical power source portion 502 a of the housing 502.

FIG. 22 further illustrates the coupler 514 engaged with the housing502. In particular, the coupler 514 may be received in the couplercavity 506. As illustrated in FIG. 23, additional components may beinserted in the coupler cavity 506. In particular, a seal 560 may beinserted through the coupler 514. Further, an electrical contact 562 mayextend through the seal 560. The seal 560 may be configured toelectrically insulate the coupler 514 from the electrical contact 562.In this regard, the electrical contact 562 may comprise a conductivematerial such as brass, and the seal 560 may comprising an electricallyinsulating material such as silicone. The electrical contact 562 may beengaged with a first terminal 564 (see, e.g., FIG. 22) of the controller510. For example, the electrical contact 562 may be welded to the firstterminal 564 after the first terminal is bent into contact therewith.

Further, a tab 566 may be engaged with the coupler 514 and received inthe coupler cavity 506 defined by the coupler portion 502 c of thehousing 502. A fastener 568 (e.g., a nut) may be secured to the coupler514 in order to retain the tab 566 in engagement therewith. The tab 566may be coupled to a second terminal 570 (see, e.g., FIG. 22) of thecontroller 510. For example, the second terminal 570 may be welded tothe tab 566 after the second terminal is bent into engagement therewith.Thereby, the coupler 514 may be electrically coupled to the controller510. In another embodiment the second terminal 570 may directly engagethe coupler 514. Regardless, positive and negative connections may beestablished with the cartridge 200″ (see, e.g., FIG. 17) when thecartridge is engaged with the control body 501 via the electricalcontact 562 and the coupler 514. Thereby, current may be directed to thecartridge 200″ in order to vaporize the aerosol precursor compositiontherein as directed by the controller 510 when a user depresses thefirst button assembly 542 (see, e.g., FIG. 18).

After the various components noted above are inserted into the couplercavity 506, the access door 502 b (see, FIG. 18) may be engaged with theelectrical power source portion 502 a and the coupler portion 502 c ofthe housing 502. Thereby, the control body 501 may define the completedconfiguration illustrated in FIG. 17.

Note that although the control bodies of the present disclosure aredescribed herein as being usable with cartridges, it should beunderstood that the term “cartridge” is intended to include embodimentsthereof referred to as “tanks” or “tank-style cartridges.” Tanks aredistinguishable from other embodiments of cartridges for aerosoldelivery devices in that they may not include a reservoir substrate, atleast a portion thereof may be transparent or translucent such that alevel of aerosol precursor composition may be viewed, and the quantityof the aerosol precursor composition that may be received therein may berelatively large. Embodiments of tank-style cartridges are described inU.S. patent application Ser. No. 14/802,667, filed Jul. 17, 2015, toO'Brien, which is incorporated herein by reference in its entirety.

In an additional embodiment a method for assembling an aerosol deliverydevice is provided. As illustrated in FIG. 24, the method may includeproviding a housing defining an electrical power source cavityconfigured to receive an electrical power source, the electrical powersource cavity defining a first longitudinal axis at operation 702.Further, the method may include engaging a coupler configured to engagea cartridge including an aerosol precursor composition with the housingsuch that the cartridge extends along a second longitudinal axis, thefirst longitudinal axis and the second longitudinal axis beingnon-coaxial and oriented substantially parallel to one another atoperation 704. Additionally, the method may include positioning acontroller in the housing, the controller being configured to engage theelectrical power source at operation 706.

In some embodiments the method may further comprise engaging theelectrical power source with the controller. Additionally, the methodmay include inserting the electrical power source in the electricalpower source cavity simultaneously with positioning the controller inthe housing at operation 706. Further, the method may include engagingthe cartridge with the coupler. The cartridge may include a viewingwindow. The method may additionally include positioning an illuminationsource in the housing, the illumination source being configured todirect illumination through the viewing window.

In some embodiments providing the housing at operation 702 may includeengaging a first body portion with a second body portion. Providing thehousing at operation 702 may further include engaging an access doorwith at least one of the first body portion and the second body portion,the access door being configured to block access to the electrical powersource cavity. Providing the housing at operation 702 may additionallyinclude engaging a button assembly with at least one of the first bodyportion and the second body portion. Further, the method may includepositioning an illumination source in the housing and engaging anillumination source cover with the button assembly, the illuminationsource cover being configured to direct illumination produced by theillumination source therethrough.

Many modifications and other embodiments of the disclosure will come tomind to one skilled in the art to which this disclosure pertains havingthe benefit of the teachings presented in the foregoing descriptions andthe associated drawings. Therefore, it is to be understood that thedisclosure is not to be limited to the specific embodiments disclosedherein and that modifications and other embodiments are intended to beincluded within the scope of the appended claims. Although specificterms are employed herein, they are used in a generic and descriptivesense only and not for purposes of limitation.

1-21. (canceled)
 22. An aerosol delivery device, comprising: a housing;an electrical power source portion defined by the housing and includingan electrical power source cavity configured to receive an electricalpower source, the electrical power source cavity defining a firstlongitudinal axis; a coupler portion engaged with the housing andincluding a coupler cavity configured to at least partially receive acartridge including an aerosol precursor composition such that thecartridge extends along a second longitudinal axis, the firstlongitudinal axis and the second longitudinal axis being non-coaxial andoriented substantially parallel to one another; an illumination source;and a button assembly engaged with the housing, the button assemblyincluding an illumination source cover configured to direct illuminationproduced by the illumination source therethrough.
 23. The aerosoldelivery device of claim 22, wherein the button assembly at leastpartially defines a wall separating the cartridge from the electricalpower source assembly.
 24. The aerosol delivery device of claim 22,further comprising a coupler present in the coupler portion.
 25. Theaerosol delivery device of claim 24, wherein the coupler is configuredto engage the cartridge when it is at least partially received in thecoupler cavity.
 26. The aerosol delivery device of claim 25, wherein thecoupler is in electrical connection with a controller.
 27. The aerosoldelivery device of claim 22, further comprising an electrical powersource.
 28. The aerosol delivery device of claim 27, wherein the buttonassembly is configured to control a power output level directed from theelectrical power source to the cartridge.
 29. An aerosol deliverydevice, comprising: a housing defining an electrical power source cavityconfigured to receive an electrical power source, the electrical powersource cavity defining a first longitudinal axis; a coupler engaged withthe housing and configured to engage a cartridge including an aerosolprecursor composition such that the cartridge extends along a secondlongitudinal axis, the first longitudinal axis and the secondlongitudinal axis being non-coaxial and oriented substantially parallelto one another; an illumination source; and a button assembly engagedwith the housing, the button assembly including an illumination sourcecover configured to direct illumination produced by the illuminationsource therethrough.